**************************************************************************
USACE / NAVFAC / AFCEC / NASA
UFGS-34 11 19.00 20 (April 2006)
-------------------------------Preparing Activity: NAVFAC
Replacing without change
UFGS-05652N (September 1999)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2016
**************************************************************************
SECTION TABLE OF CONTENTS
DIVISION 34 - TRANSPORTATION
SECTION 34 11 19.00 20
WELDING CRANE AND RAILROAD RAIL - THERMITE METHOD
04/06
PART 1
GENERAL
1.1
REFERENCES
1.2
SUBMITTALS
1.3
QUALITY ASSURANCE
1.3.1
Operator Qualification
1.3.2
Acceptable Welds
1.3.3
Procedure Qualification
1.3.3.1
Written Procedure
1.3.3.2
Manufacturer's Procedure
1.3.3.3
Welding Procedure Qualification
1.3.4
Required Data
1.3.5
Welding Procedure
1.3.6
Required Qualification Welds
1.4
DELIVERY AND STORAGE
1.4.1
Receipt Inspection of All Thermite Weld Kits
1.4.2
Material Control
PART 2
PRODUCTS
2.1
MATERIALS
PART 3
EXECUTION
3.1
SEQUENCE OF OPERATION
3.1.1
Rail Preparation
3.1.2
Rail Alignment
3.1.3
Placing of Molds
3.1.4
Preheating Rail Ends
3.1.5
Ignition of Thermite
3.1.6
Mold Removal
3.1.7
Finishing
3.1.8
Joint Records
3.2
INSPECTION AND TESTING
3.2.1
Visual Inspection
3.2.2
Nondestructive Inspection
SECTION 34 11 19.00 20
Page 1
3.2.3
Hardness Tests
-- End of Section Table of Contents --
SECTION 34 11 19.00 20
Page 2
**************************************************************************
USACE / NAVFAC / AFCEC / NASA
UFGS-34 11 19.00 20 (April 2006)
-------------------------------Preparing Activity: NAVFAC
Replacing without change
UFGS-05652N (September 1999)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2016
**************************************************************************
SECTION 34 11 19.00 20
WELDING CRANE AND RAILROAD RAIL - THERMITE METHOD
04/06
**************************************************************************
NOTE: This guide specification covers the
requirements for welding of crane rail and railroad
rail by a thermite process.
Adhere to UFC 1-300-02 Unified Facilities Guide
Specifications (UFGS) Format Standard when editing
this guide specification or preparing new project
specification sections. Edit this guide
specification for project specific requirements by
adding, deleting, or revising text. For bracketed
items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in
respective project, whether or not brackets are
present.
Comments, suggestions and recommended changes for
this guide specification are welcome and should be
submitted as a Criteria Change Request (CCR).
**************************************************************************
**************************************************************************
NOTE: The following information shall be shown on
the project drawings:
1. Location of welds.
**************************************************************************
PART 1
1.1
GENERAL
REFERENCES
**************************************************************************
NOTE: This paragraph is used to list the
publications cited in the text of the guide
specification. The publications are referred to in
the text by basic designation only and listed in
this paragraph by organization, designation, date,
and title.
SECTION 34 11 19.00 20
Page 3
Use the Reference Wizard's Check Reference feature
when you add a RID outside of the Section's
Reference Article to automatically place the
reference in the Reference Article. Also use the
Reference Wizard's Check Reference feature to update
the issue dates.
References not used in the text will automatically
be deleted from this section of the project
specification when you choose to reconcile
references in the publish print process.
**************************************************************************
The publications listed below form a part of this specification to the
extent referenced. The publications are referred to within the text by the
basic designation only.
AMERICAN WELDING SOCIETY (AWS)
AWS D1.1/D1.1M
(2015) Structural Welding Code - Steel
ASTM INTERNATIONAL (ASTM)
ASTM E10
(2015) Brinell Hardness of Metallic
Materials
ASTM E110
(2014) Indentation Hardness of Metallic
Materials by Portable Hardness Testers
U.S. DEPARTMENT OF DEFENSE (DOD)
MIL-STD-1699
1.2
(1992; Rev B) Nondestructive Evaluation of
Butt Welds in Crane and Railroad Rails
SUBMITTALS
**************************************************************************
NOTE: Review Submittal Description (SD) definitions
in Section 01 33 00 SUBMITTAL PROCEDURES and edit
the following list to reflect only the submittals
required for the project.
The Guide Specification technical editors have
designated those items that require Government
approval, due to their complexity or criticality,
with a "G". Generally, other submittal items can be
reviewed by the Contractor's Quality Control
System.
Only add a “G” to an item, if the
submittal is sufficiently important or complex in
context of the project.
For submittals requiring Government approval on Army
projects, a code of up to three characters within
the submittal tags may be used following the "G"
designation to indicate the approving authority.
Codes for Army projects using the Resident
Management System (RMS) are: "AE" for
Architect-Engineer; "DO" for District Office
(Engineering Division or other organization in the
SECTION 34 11 19.00 20
Page 4
District Office); "AO" for Area Office; "RO" for
Resident Office; and "PO" for Project Office. Codes
following the "G" typically are not used for Navy,
Air Force, and NASA projects.
An "S" following a submittal item indicates that the
submittal is required for the Sustainability
Notebook to fulfill federally mandated sustainable
requirements in accordance with Section 01 33 29
SUSTAINABILITY REPORTING.
Choose the first bracketed item for Navy, Air Force
and NASA projects, or choose the second bracketed
item for Army projects.
**************************************************************************
Government approval is required for submittals with a "G" designation;
submittals not having a "G" designation are [for Contractor Quality Control
approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for
the Government.] Submittals with an "S" are for inclusion in the
Sustainability Notebook, in conformance to Section 01 33 29 SUSTAINABILITY
REPORTING. Submit the following in accordance with Section 01 33 00
SUBMITTAL PROCEDURES:
SD-04 Samples
[
Operator qualification welds]
Procedure qualification welds
SD-06 Test Reports
Ultrasonic tests
Hardness tests
SD-07 Certificates
Rails
Welder's qualification
Welding procedure
[
Cold weather welding procedures]
[
Wet weather welding procedures]
Rail correction method
Rail preparation
SD-08 Manufacturer's Instructions
Thermite kit
SD-11 Closeout Submittals
SECTION 34 11 19.00 20
Page 5
1.3.3.2
Manufacturer's Procedure
No separate qualification is necessary for various rail weights, although
in order to be qualified for a specific rail weight or cross section, the
procedure shall include fit-up requirements and other features unique to
the rail weight or cross section of the rails to be welded.
1.3.3.3
Welding Procedure Qualification
a.
Provide welding procedure qualification records acceptable to the
Contracting Officer as proof of previous qualification under this
specification. The records shall include the information specified in
paragraph entitled "Submittals," as well as any particulars of the
process deemed pertinent to the successful completion of the welds.
b.
Welding procedure not previously qualified under this specification may
be qualified by providing four consecutive acceptable welded rail
joints. An acceptable weld is defined as a weld which has been
visually inspected and ultrasonically tested and has been found
acceptable in accordance with MIL-STD-1699 and ASTM E10. This
qualification may be accomplished either by shop fabrication of the
joints or on the first four joints welded at the work site. If
procedure qualification is accomplished at the work site, perform no
further welding until the qualification weldments have been accepted by
visual inspection and ultrasonic tests. Obtain written approval of the
acceptability of the four welded joints from the Contracting Officer
prior to continuing with welding.
c.
Ambient temperature: Welding procedure shall be considered qualified
for use at an ambient temperature of 10 degrees C 50 degrees F and
above regardless of ambient temperature during welding of qualification
assemblies. No welding shall be conducted below 10 degrees C 50
degrees F without a specifically qualified procedure. Procedures
qualified for use at ambient temperatures less than 10 degrees C 50
degrees F shall be qualified by welding test assemblies in accordance
with the procedure qualification requirements of this specification at
the desired minimum ambient temperature plus or minus one degree C 5
degrees F. Procedures thus qualified shall be considered acceptable
for use at the minimum qualified ambient temperature and above.
d.
Wet weather welding: Perform welding only during dry weather. No
welding will normally be permitted on wet, showery and inclement days.
However, if means are provided to protect the work and work area,
welding may be performed during other than dry weather, if approved by
the Contracting Officer. Welding in confined spaces shall comply with
AWS D1.1/D1.1M to assure adequate ventilation for personnel safety.
1.3.4
Required Data
Submit thermite kit manufacturer's instructions and recommendations
covering rail end preheat treatment, thermite ignition, mold removal, and
finishing.
1.3.5
Welding Procedure
a.
Thermite kit manufacturer's name and kit size or designation
b.
Thermite kit batch numbers and manufacturing date
SECTION 34 11 19.00 20
Page 7
1.3.3.2
Manufacturer's Procedure
No separate qualification is necessary for various rail weights, although
in order to be qualified for a specific rail weight or cross section, the
procedure shall include fit-up requirements and other features unique to
the rail weight or cross section of the rails to be welded.
1.3.3.3
Welding Procedure Qualification
a.
Provide welding procedure qualification records acceptable to the
Contracting Officer as proof of previous qualification under this
specification. The records shall include the information specified in
paragraph entitled "Submittals," as well as any particulars of the
process deemed pertinent to the successful completion of the welds.
b.
Welding procedure not previously qualified under this specification may
be qualified by providing four consecutive acceptable welded rail
joints. An acceptable weld is defined as a weld which has been
visually inspected and ultrasonically tested and has been found
acceptable in accordance with MIL-STD-1699 and ASTM E10. This
qualification may be accomplished either by shop fabrication of the
joints or on the first four joints welded at the work site. If
procedure qualification is accomplished at the work site, perform no
further welding until the qualification weldments have been accepted by
visual inspection and ultrasonic tests. Obtain written approval of the
acceptability of the four welded joints from the Contracting Officer
prior to continuing with welding.
c.
Ambient temperature: Welding procedure shall be considered qualified
for use at an ambient temperature of 10 degrees C 50 degrees F and
above regardless of ambient temperature during welding of qualification
assemblies. No welding shall be conducted below 10 degrees C 50
degrees F without a specifically qualified procedure. Procedures
qualified for use at ambient temperatures less than 10 degrees C 50
degrees F shall be qualified by welding test assemblies in accordance
with the procedure qualification requirements of this specification at
the desired minimum ambient temperature plus or minus one degree C 5
degrees F. Procedures thus qualified shall be considered acceptable
for use at the minimum qualified ambient temperature and above.
d.
Wet weather welding: Perform welding only during dry weather. No
welding will normally be permitted on wet, showery and inclement days.
However, if means are provided to protect the work and work area,
welding may be performed during other than dry weather, if approved by
the Contracting Officer. Welding in confined spaces shall comply with
AWS D1.1/D1.1M to assure adequate ventilation for personnel safety.
1.3.4
Required Data
Submit thermite kit manufacturer's instructions and recommendations
covering rail end preheat treatment, thermite ignition, mold removal, and
finishing.
1.3.5
Welding Procedure
a.
Thermite kit manufacturer's name and kit size or designation
b.
Thermite kit batch numbers and manufacturing date
SECTION 34 11 19.00 20
Page 7
c.
Welding procedure designation (name, number)
d.
Size of rail section being joined and type of rail
e.
Test assembly identification number
f.
Results of nondestructive testing of qualifications assemblies
g.
Date of qualification (test date)
1.3.6
Required Qualification Welds
Submit operator qualification welds in accordance with paragraph entitled
"Operator Qualification." Submit procedure qualification welds in
accordance with paragraph entitled "Welding Procedure Qualifications."
Include results of ultrasonic test and hardness tests. Welders
certification or procedure qualification may be substituted, pursuant to
paragraph entitled "Quality Assurance."
1.4
DELIVERY AND STORAGE
Deliver materials in the manufacturer's original unbroken packages or
containers plainly labeled with the manufacturer's name and brand.
1.4.1
Receipt Inspection of All Thermite Weld Kits
Shall consist of a visual inspection of the weld kit package for freedom
from damage and the recording of the thermite weld mix batch number and
manufacturing date. Do not use kits which have been manufactured more than
2 years before the date of use or show signs of having been wet.
1.4.2
Material Control
Store materials in the original package and keep dry at all times until
used.
PART 2
2.1
PRODUCTS
MATERIALS
Provide in kit form including preformed mold, thermite powder, wicking
cord, luting material, and all necessary materials and accessories needed
to provide one welded rail joint per kit. Molds shall be factory-made,
moisture free, and of nonhygroscopic material.
PART 3
3.1
EXECUTION
SEQUENCE OF OPERATION
Perform work in strict accordance with the qualified procedure.
3.1.1
Rail Preparation
Cut rails which are battered, cracked or notched, or which contain bolt
holes so that these irregularities are removed. Rail surface shall be free
of grease, dirt, loose oxide, and moisture on the face of and for
approximately 125 mm 5 inches from the joint to be welded. Clean rail ends
by grinding or wire brushing. Use a torch to remove grease, oil, or
moisture in accordance with procedures in thermite manufacturers
SECTION 34 11 19.00 20
Page 8
instructions. Rail cutting, when necessary, shall be by the saw-cut
method. Remove all burrs, rolled-over edges, and loose oxide before
applying the mold. No flame cutting of rails is permitted. If the space
between the mold and the rail is unusually large on used or relayer rails,
fill this gap with a piece of wicking cord before luting or packing.
3.1.2
Rail Alignment
Separate rail ends as recommended by the welding process manufacturer.
Align rails as to both surface and gage, and raise the rails at the joint
to compensate for the greater thermal contraction that occurs in the rail
head during cooling relative to the web and base regions. Measure the
amount of joint elevation with a 900 mm 36 inch long straightedge centered
at the joint. The correct elevation is obtained when 2 mm 1/16 inch
separates the top of the rail head and bottom surface of the straightedge
at both ends.
3.1.3
Placing of Molds
Attach the molds to the rails, centered over the joint, and seal the molds
to the rail with luting material according the welding kit manufacturer's
instructions. Handle the luting material, a mixture of clay and sand, so
that none is introduced into the weld chamber. Align so that the
centerline of the mold coincides with the centerline of the gap. Install
the tapping plug or discs in the crucible and pour in the prescribed amount
of thermite mixture.
3.1.4
Preheating Rail Ends
In accordance with the manufacturer's instructions and recommendations.
3.1.5
Ignition of Thermite
Follow manufacturer's instructions and recommendations.
3.1.6
Mold Removal
Follow manufacturer's instructions.
3.1.7
Finishing
Follow manufacturer's instructions and recommendations. No finishing is
required on the web and base of rail. Perform final grinding when the weld
and rail have cooled to ambient temperature. Under no circumstances shall
a cutting torch be used to remove excess weld metal.
3.1.8
Joint Records
Provide a record of the date and location of each weld made. The record
shall also include the rail type, size, thermite kit manufacturer's name,
and thermite weld portion batch number. Also, provide a record of the
nondestructive test date and acceptance date.
3.2
3.2.1
INSPECTION AND TESTING
Visual Inspection
Each welded joint by shall be inspected by the Contractor after removal of
the mold and grinding or removal of excess metal. The inspector shall pay
SECTION 34 11 19.00 20
Page 9
particular attention to surface cracking, lack of fusion and other surface
irregularities. The Contractor shall correct or replace all defective
welds at no additional cost to the Government. The method of correction
shall be approved by the Contracting Officer.
3.2.2
Nondestructive Inspection
Inspect each welded joint by ultrasonic tests using the method of
inspection and acceptance as prescribed in MIL-STD-1699. The Contractor
shall correct or replace all defective welds at no additional cost to the
Government. The method of correction shall be approved by the Contracting
Officer. All repairs to defective welds shall be ultrasonically inspected
by the Contractor using the method of inspection and acceptance as
prescribed in MIL-STD-1699.
3.2.3
Hardness Tests
Perform Brinell hardness test in accordance with ASTM E10 and ASTM E110.
The Brinell Hardness Number (BHN) of the weld and for the rail for a
distance of 150 mm 6 inches on each side of the joint shall be greater than
250. In the heat-affected zone (a distance not greater than 25 mm one inch
to each side of the joint) the BHN may be up to 20 points lower except for
the top of the rail, which shall be not less than 250. Check hardness on
at least 10 percent of all welds. Tests shall be performed on randomly
selected welds or as directed by the Contracting Officer.
-- End of Section --
SECTION 34 11 19.00 20
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